U.S. patent number 8,336,113 [Application Number 12/661,066] was granted by the patent office on 2012-12-25 for cool, clean air welding helmet.
Invention is credited to Gerald Daniel Uttrachi.
United States Patent |
8,336,113 |
Uttrachi |
December 25, 2012 |
Cool, clean air welding helmet
Abstract
An improved welding helmet encloses a welders head and a portion
of the neck. The helmet contains a fan, filter and thermoelectric
cooling module to provide clean, cool air that reduces welding fume
levels below suggested maximums and provides cool air to the
welders head and neck area making their body feel cooler. Air
exhausted from the helmet is captured and further utilized to
significantly improve system efficiency by causing it to be in
contact with the hot side heat sink that is a part of the
thermoelectric cooling module assembly. The use of an external
power source, including readily available welding power, is
suggested as one option for supplying system power. An optional
configuration is presented where an external container strapped to
the welders body is employed containing the fan, air filter and
thermoelectric cooling module and is connected to the helmet by
cool air intake and exhaust air hoses.
Inventors: |
Uttrachi; Gerald Daniel
(Florence, SC) |
Family
ID: |
44558478 |
Appl.
No.: |
12/661,066 |
Filed: |
March 10, 2010 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20110219506 A1 |
Sep 15, 2011 |
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Current U.S.
Class: |
2/8.6; 2/171.3;
2/7 |
Current CPC
Class: |
A61F
9/067 (20130101) |
Current International
Class: |
A61F
9/06 (20060101); A42C 5/04 (20060101); A61F
9/00 (20060101) |
Field of
Search: |
;2/7,8.1-8.8,171.3,209.13,905,906,422,435,436,437
;128/201.22,201.25,863 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Chino Hayashi and Hiromi Tokura; "Effects of Head Cooling on Sweat
Rate in Exercising Subjects Wearing Protective Clothing and Mask
for Pesticide"; Applied Human Science Journal of Physiological
Anthopology vol. 15 (1996), No. 4 pp. 149-154 See Abstract which
provides a good summary showing sweat on arms reduced with head
cooling etc. cited by other .
U.S. Appl. No. 12/455,067, filed May 29, 2009, Gerald D. Uttrachi.
cited by other.
|
Primary Examiner: Self; Shelley
Assistant Examiner: Yoon; Jane
Claims
I claim:
1. A hose supplied helmet apparatus that encloses the front, right
side, left side, top and back of the head of a welding operator and
comprises: a) an auto-darkening welding lens located in the front
portion of said hose supplied helmet apparatus that when an
electric arc is present changes from essentially transparent to a
dark shade, and b) a skirt added to said hose supplied helmet
apparatus wherein said skirt is made of a flexible, fire resistant
material and attaches to the bottom of said hose supplied helmet
apparatus to seal said skirt to said hose supplied helmet
apparatus, and c) wherein said skirt may be attached to said hose
supplied helmet apparatus such that it provides some portion of the
enclosure of the back, sides and rear portion of the top of said
hose supplied helmet apparatus, and d) a tie means located around
said skirt to bring said skirt in close proximity to the neck of
said welding operator, and e) said skirt may be of sufficient
length to be placed under a shirt or jacket collar, and f) an
external container is part of the hose supplied helmet apparatus to
which a suitable belt or shoulder straps is affixed, allowing said
welding operator to carry said external container on the body of
the welding operator, and g) wherein one construction arrangement
of said external container has two internal sections separated by
an internal baffle of a predetermined thickness, an input air
section and an exhaust air section, and h) an air filter is located
at one end of said input air section of said external container to
capture harmful particles of welding fume and prevent them from
passing through said air filter, and i) an electric motor powered
cooling fan is located in said input air section, and j) an
electrically powered thermoelectric cooling module is sandwiched
between a hot heat sink and a cold heat sink, and k) both said hot
heat sink and said cold heat sink have a heat transfer surface
consisting of fins or pins for providing a heat transfer surface,
and l) said heat transfer surface of said cold heat sink is located
in said input air section such that the air passing through said
air filter communicates with said cold heat sink, and m) said air
passing through said air filter transports cooled, clean air
through a cooled air opening located at the opposite end of said
input air section from the end having said air filter where said
cooled air opening is approximately the same cross sectional area
as an inlet cooled air hose of a predetermined cross section that
is attached over said cooled air opening, and n) said inlet cooled
air hose transports said cooled, clean air to the top front section
of said hose supplied helmet apparatus and said inlet cooled air
hose is attached over an inlet opening in said hose supplied helmet
where said inlet opening is approximately the same cross sectional
area as said inlet cooled air hose and the cooled, clean air
passing through said inlet opening communicates with the head and
face of said welding operator, and o) one end of an exhaust air
hose of a predetermined size is attached over at an exhaust opening
located in said hose supplied helmet apparatus where said exhaust
opening is approximately the same cross sectional area as said
exhaust air hose and said exhaust air hose transports a majority of
the air that entered said hose supplied helmet apparatus from said
inlet cooled air hose, and p) the opposite end of said exhaust air
hose from the end attached to said hose supplied helmet is attached
over an exhaust inlet opening located at one end of said exhaust
air section of said external container where said exhaust inlet
opening is approximately the same cross sectional area as said
exhaust air hose, and q) said heat transfer surface of said hot
heat sink is located in said exhaust air section, and r) the
exhaust air entering said exhaust air section is directed so it is
in communication with said hot heat sink before being expelled to
the outside atmosphere through an opening located at the opposite
end of said exhaust air passage from the end where said exhaust air
hose is attached, and s) a power wire is attached to said external
container and supplies electric power to said cooling fan and said
thermoelectric cooling module from an outside source.
2. The hose supplied helmet apparatus of claim 1, wherein said
power wire is replaced with a portable power source for supplying
power and said portable power source is affixed to said external
container or to an alternate means adaptable to be attached to the
body of said welding operator.
3. The hose supplied helmet apparatus of claim 1, wherein said hose
supplied helmet apparatus is powered by a DC power source having a
voltage below about 24 volts obtained from a DC converter powered
from an AC power source or a DC power source supplied by a welding
power source employing an AC/DC to DC converter connected to said
welding power source.
4. The hose supplied helmet apparatus of claim 1, including a
control module and a temperature control knob such that a welding
operator can adjust the desired temperature.
5. The hose supplied helmet apparatus of claim 4, wherein said
power wire is replaced with a portable power source for supplying
power and said portable power source is affixed to said external
container or to an alternate means adaptable to be attached to the
body of said welding operator.
6. The hose supplied helmet apparatus of claim 4, wherein said hose
supplied helmet apparatus is powered by a DC power source having a
voltage below about 24 volts obtained from a DC converter powered
from an AC power source or a DC power source supplied by a welding
power source employing an AC/DC to DC converter connected to said
welding power source.
7. The hose supplied helmet apparatus of claim 1, including an
electrically powered hot heat sink fan that is located in said
exhaust air passage to increase air flow and further increase
cooling of said hot heat sink.
8. The hose supplied helmet apparatus of claim 7, wherein said
power wire is replaced with a portable power source for supplying
power and said portable power source is affixed to said external
container or to an alternate means adaptable to be attached to the
body of said welding operator.
9. The hose supplied helmet apparatus of claim 7, wherein said hose
supplied helmet apparatus is powered by a DC power source having a
voltage below about 24 volts obtained from a DC converter powered
from an AC power source or a DC power source supplied by a welding
power source employing an AC/DC to DC converter connected to said
welding power source.
10. The hose supplied helmet apparatus of claim 1, wherein said
hose supplied helmet apparatus is constructed so as to also meet
the requirements of a hard hat.
Description
BACKGROUND
1. Field of Invention
This welding helmet invention improves welder comfort using a
thermoelectric device and a quality filter to deliver clean, cool
air to a welders head and neck. It utilizes an innovative design to
more than double the energy efficiency required to achieve the very
positive result.
2. Background
Welding is considered a hot and dirty occupation by many
professional welders. Recently, allowable maximum levels of fume
constituents from arc welding are at such low levels that
conventional means of staying below these levels are not
sufficient. For example, the current maximum recommended fume
exposure level for some chrome (VI) compounds is 0.01 mg/m.sup.3.
Even employing source capture may not be sufficient to assure
welder exposure levels are below that maximum safe level. When
welding steel, some fume constituents may also exceed newly reduced
maximum fume constituent levels. This may require a welder to use a
high quality respirator under their normal welding helmet making
the hot working environment even more objectionable. Welding often
occurs in shops which are not cooled in warm weather and the use of
devices such as respirators makes the welding occupation less
attractive. When welding in very toxic environments air has been
delivered to welding helmets from an external source through a long
hose. This is not practical or desirable for most welding
applications.
3. Description of Prior Art
There have been welding helmet designs that attempt to address some
of the environmental problems encountered while welding: (a)
Walters in U.S. Pat. No. 3,548,415 (1968) entitled "Air Conditioned
Helmet," describes a device that incorporates a fan enclosed in an
open helmet, not one used for welding. It discusses several means
of creating cooling such as gels, heat pipes and mentions but does
not elaborate on the possible use of a thermoelectric principle. As
with many of the devices reviewed, this one relies on battery
power. It also does not mention any means of reducing welding fume
levels to a very low level nor would the design with its open
helmet arrangement accomplish this task. (b) Greenlee in U.S. Pat.
No. 3,535,707 (1970) entitled "Welding Helmet and the Like,"
describes a welding helmet with a fan in the front which draws air
from the rear of the helmet. The back of this helmet, as with most
welding helmets, is open. At the very low allowable concentrations
of some welding fume constituents this approach would not provide
sufficiently low fume breathing air in many welding applications.
(c) Martin, et al in a US patent application 2007/0056073 entitled
"Modular Auto-Darkening Welding Filter," discusses a feature that
would be used in this invention, an adjustable shade auto-darkening
welding lens using external knobs to adjust some of the functions
of the helmet. External adjustment of auto-darkening welding lens
shade is common to some commercial welding helmets. (d) Apisdorf in
U.S. Pat. No. 5,193,317 (1993) and reissue Pat. RE 36,242 (1999)
entitled "Helmet-Mounted Air System for Personal Comfort,"
describes the use of a helmet that incorporates a thermoelectric
device to cool the air brought in by a fan. The helmet is open such
that the cool air exits the helmet after passing the welders face
one time and the cool air does not assist cooling the
thermoelectric hot side heat sink. The patent claims the use of a
battery that is body mountable to power the device. They discuss
the small amount of cooling the device provides and justify the low
amount as being sufficient to cause comfort. They emphasize the
cool air is brought to the face and the design shows it exits the
helmet area after it enters. They appear to justify low levels of
flow and a small amount of cooling to support a key claim for the
device of being capable of using a body mountable battery. (e)
Buckman in U.S. Pat. No. 7,534,005 (2009) entitled "Welding
Helmet," and prior U.S. Pat. No. 7,178,932 describes the use of
multiple fans and a filter. One figure also shows a type of helmet
skirt. However, the claims describe a conventional welding helmet
with only front and sides, not the back or the top of the welders
head covered. There is also no mention of a cooling device of the
thermoelectric type or of any type that would significantly improve
the welder's temperature environment. (f) Johnson in U.S. Pat. No.
5,896,579 describes a welding helmet with a fan and a device for
employing evaporation cooling. As with most of the prior art
discovered the helmet described also has a typical open back and
would not provide the sufficiently clean breathing air needed in
many welding environments. (g) Goldsborough in U.S. Pat. No.
7,296,304 describes a race car crash helmet that contains Peltier
thermoelectric modules located around the periphery of the helmet
shell. However the cooled air exits the helmet at the bottom and
other openings and is not sealed. This patent does discuss
providing power from a cigarette lighter receptacle which is
readily available in a conventional automobile. However there is no
attempt to filter the air or improve efficiency by using the cooled
air exhausted from the helmet to assist in cooling the
thermoelectric hot side heat sinks.
SUMMARY, OBJECTS AND ADVANTAGES
It is the object of this present invention to provide cool, clean
air to a welder by incorporating a number of unique elements and
features in a helmet design for the welding profession. Studies
have shown that head cooling reduces sweating in other parts of the
body. These features provide an improved environment for the welder
and cause welders to desire to use the device because of the
improved working conditions. The device further utilizes clean,
cooled air exiting the helmet to improve the energy efficiency of
the thermoelectric cooling module by causing the helmet exhaust air
to flow through the thermoelectric module hot side heat sink. In
tests of this hot heat sink cooling approach a surprising result
was found. Over twice the amount of temperature reduction was
achieved by utilizing the helmet exhaust air to help cool the hot
side heat sink compared to when it was not employed.
This welding helmet is also unique compared to what is used in
industry and that defined in prior art. One unique feature is the
functional shape of the welding helmet. One embodiment has an
external shape like an automotive racing helmet or a full face
motorcycle helmet. That is, not only is it enclosed on the front
and sides but also on the top and back. It utilizes a skirt made
from a flexible material attached to the bottom of the helmet
opening. The skirt can be placed snuggly around the neck with an
appropriate tie device and or tucked into a shirt or welding jacket
to assist in capturing the cooled helmet exhaust air. The skirt
will also reduce the intrusion of outside air which may have
excessive levels of potentially harmful fumes. Unlike a racing or
motorcycle helmet the current invention can be made from light
weight materials only having to meet penetration tests to be
certified by the American National Standards Institute. If desired
it could be constructed to also meet the requirements for a hard
hat where needed in construction, shipyards and in many
manufacturing plants.
By employing an enclosed helmet it is possible to use a fan to
assure breathing air passes through a quality replaceable filter
designed to capture potentially harmful welding fume particles. Two
versions of the helmet device are defined. In one version, the
filter is placed at the back of the helmet where it is exposed to
the least amount of welding fume. Air entering the helmet is
channeled through an internal passageway near the top of the helmet
above a head band. The head band provides for a custom fit for the
wearer. A thermoelectric cooling module powered by a DC electric
current causes one surface to become cooler than ambient and the
other to become hotter. The thermoelectric module utilizes finned
or a pin type heat sink on both cool and hot sides. The cold side
heat sink is placed in an air passageway with the filter on one
end. An internal fan causes filtered air to come in contact with
the cold heat sink before routing past the welders face and head.
The thermoelectric modules hot heat sink heat transfer surface is
placed outside the surface of the helmet and dissipates heat to the
outside air. To significantly assist in removing heat from the hot
side heat sink, the air exhausted from the helmet having
accomplished the task of cooling the welders face can be channeled
to the hot side heat sink. A cowl arrangement is employed to focus
the cooled clean air to maximize contact with the heat sink. The
electric powered fan has sufficient power to provide the needed air
flow to meet the welders breathing health and safety requirements.
Optionally an additional fan can be placed on or near the hot side
heat sink to assist overall air movement and to enhance heat
removal. It was discovered by using the cool helmet exhaust air to
help cool the thermoelectric modules hot side heat sink over twice
the reduction in air temperature was be achieved. In addition, this
cooled, clean air helps reduce the hot heat sinks exposure to
welding fumes and metal grinding dust. Keeping the heat sink clean
is important to maintaining system performance.
The welding lens employed should be of an auto-darkening type. When
an arc is struck it switches from essentially a clear lens to one
darkened sufficiently to protect the welder's eyes from the arc
rays. It allows good vision when not welding and provides adequate
blockage of arc rays when welding. It is possible to hinge the
portion of the helmet containing the auto-darkening lens mechanism
so it can be raised allowing the welder an opening directly to the
outside. This requires a quality sealing system to avoid welding
fumes entering around the helmet section containing the lens. It is
also possible to have a clear material covering the opening when
the hinged portion of the helmet with the auto-darkening lens is
raised. This would protect the welder so they might be able to
grind or perform fitting tasks while maintaining the cool
environment. Since a number of viable mechanisms are available that
would facilitate this possible embodiment, it is assumed one
skilled in the art could implement this feature if desired and
details are not covered in the patent claims.
The second version of the helmet device is one where the
thermoelectric module, heat sinks, filter and fan(s) are located in
a separate canister that the welder can carry using shoulder
straps, a belt or backpack. Cool, clean air is created in the
canister and flows through a hose to the top-front of the welding
helmet where it cools the welder. Helmet exhaust air is transported
through an exhaust hose to a section of the canister past the hot
side thermoelectric module heat sink also located in that section.
This approach provides for the use of a lighter helmet.
Supplying power for the helmet or external canister version for a
desired length of time may be difficult to achieve with a
reasonable weight of batteries. Other energy storage devices which
have more energy storage per a given weight than a battery may be
viable such as fuel cells or mechanical energy storage devices. In
addition, several unique characteristics of welding provide an
opportunity to power the clean, cool welding helmet with minimum
connections and without long electrical lines, namely: a) Arc
welding requires a great deal of electrical energy. The major
welding process used in industry is referred to as MIG welding
(Metal Inert Gas) or the official designation in the US is Gas
Metal Arc Welding (GMAW.) The term MIG welding will be used for
this patent. MIG welding employs a continuously fed wire made of
either steel, aluminum, stainless steel or other metal depending on
the material being welded. For steel and stainless steel the wire
can be solid or a product called cored wire where granular powder
or flux ingredients are placed in the center of a tubular wire
structure. Over 99% of these MIG welding processes utilize DC
welding power ranging, for industrial systems, from 200 to 600
amperage capacity. Welding voltage typically ranges from 20 to 35
volts. It is possible to connect the helmet to this source to power
with no ill effects on welding machine performance. Since welder
safety is of paramount importance it is desirable to have the
voltage going to the helmet to be less than about 24 volts. It is
possible to reduce the welding voltage through appropriate
circuitry and provide power at a safe voltage such as 12 to 18
volts. Since the MIG welding torch is typically about 3 meters in
length, connecting the required DC power wire from the helmet to
this low voltage DC source at the MIG wire feeder will require a
minimum length power wire. With most MIG welders the DC voltage is
not available when welding is stopped. It may be desirable to have
the helmet powered between welds. Therefore, a battery could be
incorporated in the DC converter device. Since MIG wire feeders are
generally somewhat bulky and heavy, often including 20 kg or more
of wire, the extra weight of a battery would normally not be a
problem when placed at this location. The DC converter device could
incorporate a system that charged the battery when welding. There
would also be a ground connection needed to power the converter
which could be connected to the work piece where the welding ground
cable is attached. b) Stick welding is another common arc welding
process used in industry and provides and even easier method of
powering the helmet. The formal designation for this process is
Shielding Metal Arc Welding (SMAW.) Stick welding will be used to
describe the process in this patent. In most instances, stick
welding power supplies are energized with welding voltage whether
an arc is struck or not. Therefore a converter to create the low
voltage DC power can be relatively small and compact. Even if the
stick welding power is AC it can easily be converted to low voltage
DC required for powering the helmet. The helmet power wire could be
connected between the stick power line coming from the power supply
and the short length of power cable that is usually attached to the
stick electrode holder which is held by the welder. The cable
supplying power to the helmet could be less than 3 or 4 meters
long. The welding operator would connect their helmet power wire to
the DC converter located where the stick electrode holder is
connected to the stick power line. There would also be a ground
connection needed to power the converter which can be connected to
the work piece where the welding ground cable is attached. c) If
desired, a power supply system could be used that is similar to
that employed to power a laptop computer or other devices that
operate at low DC voltage. As with computer power supplies it could
be plugged into any available AC power source. Many welding power
supplies incorporate auxiliary AC power receptacles to power
devices such as grinders. These AC receptacles can be conveniently
used to provide the required helmet power. d) A fourth alternative
to power the self contained helmet for a limited time could be the
use of a backpack to carry a rechargeable battery or a fuel cell or
an electromechanical energy storage device or other suitable energy
storage device. These portable power device options could be
attached directly to the canister version of the cool, clean helmet
system.
There are several advantages of the proposed device over
alternatives. To meet the increasingly lower maximum fume exposure
levels, the use of quality respirators may be the only alternative
choice for a number of applications. Respirators, even when used
correctly, require a doctor to define if a worker is capable of
breathing through these devices for an 8 hour day. Breathing
through a respirator creates more stress on the heart. Some welders
elect to have beards or mustaches. Facial hair is usually not
allowed to properly fit a quality respirator. The heat involved
when welding is often a complaint of welders. The potential to have
a cooler work environment will offset the somewhat more confining
helmet. The use of this helmet is a better alternative than using a
conventional welding helmet and wearing a respirator.
Several additional benefits occur when having a fully enclosed
welding helmet. The hot sparks from welding, called spatter, are
prevented from hitting the top and back of the head causing burns.
This is particularly an issue with current welding helmets when
welding overhead or when other welders are in the immediate area.
The proposed helmet also employs a skirt material that protects the
neck area from spatter hitting the skin eliminating burns.
DRAWING FIGURES
FIG. 1 is a left side view of the helmet, skirt, skirt tie, filter,
exhaust air passage and cowling.
FIG. 2 is the right side view of the helmet, hot side heat sink and
temperature control knob.
FIG. 3 is a left side helmet cutaway view showing baffle, air
passageway, fan, head band, exhaust air passage, hot and cold heat
sinks and control module.
FIG. 4 is a left side helmet view with a cutaway of the cowling and
hot side heat sink.
FIG. 5 is a view of the separate canister helmet system with
external power.
FIG. 6 is a view of the canister helmet system with a self
contained energy source.
FIG. 7 is a large view of the canister portion of the helmet system
shown in FIG. 6.
FIG. 8 is a thermoelectric module shown sandwiched between the hot
and cold side heat sinks.
FIG. 9 is a DC converter connected to an AC power source to power
the helmet.
FIG. 10 is an AC/DC converter attached to stick welder power to
power the helmet.
FIG. 11 is a DC converter attached to MIG welder power to power the
helmet.
FIG. 12 is a portable power source that can be affixed to a welder
with a strap arrangement.
FIG. 13 is a possible quick connect device to help manage the
helmet power tether.
FIG. 14 is an end view of the quick connect device shown in FIG.
13.
FIG. 15 shows the helmet with a possible swing away front
section.
DESCRIPTION
Main Embodiment
FIG. 1 illustrates a welding helmet 20 as viewed from the left
side. The visible elements include helmet 20 that encloses the
welding operators head in the front, right side, left side, top and
back. A raised area at the top of helmet 20 contains an internal
air passageway 125 FIG. 3 that exists between a helmet baffle 120
FIG. 3 and the top inner surface of helmet 20. Helmet air filter 50
is located at the rear of helmet 20 and the inlet end of the
internal air passageway 125 FIG. 3. The hot heat sink cowling 80
surrounds the helmet hot heat sink 90 FIG. 3 on all but one open
side and is in intimate contact with a thermoelectric module 330
FIG. 8 that is not viable but is sandwiched between the helmet hot
sink 90 FIG. 3 and helmet cold heat sink 150 FIG. 3, both of which
are partially visible in FIG. 3. A portion of the auto-darkening
welding lens 60 is shown. Also visible is a skirt 30 that is
attached to the bottom opening of the helmet 20 and minimizes
external welding fumes from entering the helmet 20 and also assists
in having a majority of the clean cooled air exiting helmet 20
passing through helmet exhaust air passage 70 and hot heat sink
cowling 80. A tie 40 can be used to secure skirt 30 to the welding
operator's neck. Skirt 30 can be of sufficient length to tuck under
the welding operators shirt or welding jacket.
FIG. 2 illustrates helmet 20 as viewed from the right side. Helmet
filter 50, welding lens 60, skirt 30 and tie 40 are visible. Hot
heat sink 90 and the opening to the atmosphere of hot heat sink
cowl 80 are shown. Helmet temperature control knob 100 is connected
to helmet control module 160 FIG. 3.
FIG. 3 shows a cutaway view of the left side of helmet 20 showing
most of the key elements. Air flow is shown with arrows. The
elements not previously shown include: helmet baffle 120 that
directs air from helmet filter 50 through internal air passageway
125 past cold heat sink 150 to helmet cooling fan 110. Headband
140, helmet control module 160 and helmet vent opening 115 are also
shown. The thermoelectric module 330 FIG. 8 is not shown since it
is sandwiched between helmet cold heat sink 150 and helmet hot heat
sink 90. A portion of helmet power wire 130 is also shown. The
voltage proved by helmet power wire 130 should be limited to about
24 volts to enhance welder safety.
FIG. 4 is similar to FIG. 2 with the addition of an optional helmet
hot heat sink fan 170 shown in a partial cutaway of hot heat sink
cowling 80. Helmet 20, helmet filter 50, welding lens 60, skirt 30,
tie 40 and helmet temperature control knob 100 are visible.
FIG. 8 shows a generic assembly of a thermoelectric module 330
sandwiched between hot heat sink 350 and cold heat sink 360.
Thermoelectric module 330 is very thin and must be in intimate
contact with hot heat sink 350 and cold heat sink 360. To be
functional, baffle 370 must generally be thicker than
thermoelectric module 330 so the hot heat sink 350 is shown having
a thicker section 355 at the bottom to allow for the different
thicknesses. The modular power wires 340 shown would be connected
to either helmet control module 150 FIG. 3 or container control
module 290 FIG. 5 or if neither is employed could be connected
directly to thermoelectric module 330, helmet cooling fan 110 FIG.
3 or container cooling fan 220 FIG. 5. The cooling fins for hot
heat sink 350 and cold heat sink 360 are shown parallel to each
other as they would probably be as used with external container 180
FIG. 5 assembly however they can be at any angle if air flow is in
different directions.
FIG. 9 shows a way to power helmet 20 FIG. 1 or external container
180 FIG. 5 using an AC power source with a DC converter 380. The DC
converter 380 produces low voltage DC power for welder safety.
Power wire 390 can be connected directly to helmet 20 FIG. 1 or
external container 180 FIG. 5. Plug 400 would fit into a normal AC
electrical receptacle.
FIG. 10 shows a way to power helmet 20 FIG. 1 or external container
180 FIG. 5 by connecting to AC/DC Stick welding power using AC/DC
low voltage converter 410. AC/DC low voltage converter 410 converts
the higher voltage power from a Stick welding power to a safer low
voltage DC. If the Stick welding power is AC the AC/DC low voltage
converter 410 changes the AC power to low voltage DC. The AC/DC
converter 410 connects between the Stick electrode holder 420 and
the welding power line 425. The AC/DC low voltage converter 410
also has a ground wire connection 427 that can be attached where
the welding power ground is connected.
FIG. 11 shows a way to power helmet 20 FIG. 1 or external container
180 FIG. 5 by connecting to a MIG wire feeder power 430 using DC
low voltage converter 440. DC low voltage converter 440 produces a
safer low DC voltage. DC low voltage converter 440 can be connected
directly at the MIG wire feeder 430 where welding power is
available using feeder power wire 450. The DC low voltage converter
440 also has a MIG ground wire 455 that can be attached where the
welding power ground is connected.
FIG. 12 shows how helmet 20 FIG. 1 could be powered using an
external energy storage device 460. The energy storage device 460
can be carried by the welder with appropriate means such as a
strap, belt 250 or backpack. It could utilize rechargeable
batteries, a fuel cell or similar device for providing electrical
power. Power wire 390 connects directly to helmet 20 FIG. 1 or
indirectly through an appropriate connector, such as energy source
connector 480 FIG. 13.
Operation
Main Embodiment
Referring to FIG. 1. A welder places helmet 20 over their head
having previously adjusted the head band 140 FIG. 3 for the proper
fit. Skirt 30 is tucked under the welder's shirt and or the tie 40
is tightened so that the skirt 30 causes a majority of the air
coming through helmet air filter 50 to be channeled through helmet
vent opening 115 FIG. 3 through exhaust passage 70 to hot heat sink
cowling 80 past helmet hot heat sink 90 FIG. 3. The welder than
connects the helmet power wire 130 FIG. 3 to an appropriate power
source such as defined in FIG. 9, FIG. 10, FIG. 11 or FIG. 12. Once
power is supplied, the helmet cooling fan 110 FIG. 3 starts and
pulls air though helmet air filter 50 through helmet vent opening
115 FIG. 3 into internal air passageway 125 FIG. 3. Power is also
supplied to a thermoelectric module 330 FIG. 8 which is sandwiched
between helmet hot heat sink 90 and helmet cold heat sink 150. The
resulting stream of air in internal air passageway 125 FIG. 3 will
contact the cool surface of helmet cold heat sink 150 reducing the
air temperature. Helmet cold heat sink 150 and helmet hot heat sink
90 are constructed of a thermally conductive material and may
contain cooling fins or pins to increase surface area. The welder
immediately receives cool, clean air delivered over their head and
face. The helmet air filter 50 would be replaced periodically as it
becomes clogged with welding fumes, metal dust from grinding
etc.
Referring to FIG. 2. In addition to the above operating description
also shown is container temperature control knob 100. It is
connected to a helmet control module 160 FIG. 3. The helmet
temperature control knob 100 is used by the welding operator to
adjust the air temperature to the desired level. The helmet control
module 160 FIG. 3 uses a suitable means such as lowering voltage to
adjust the amount of cooling achieved by the thermoelectric module
330 FIG. 8 that is sandwiched between the helmet hot heat sink 90
and the helmet cold heat sink 150 FIG. 3. A device could be
incorporated in helmet control module 160 FIG. 3 to sense and
adjust the temperature to a preset level automatically. The design
of such devices is readily achievable by one skilled in the art and
is not covered in this patent.
Description and Operation
Additional Embodiments
Referring to FIG. 5. An alternate configuration that provides a
lighter helmet utilizes an external container 180 to house the
required system elements, namely: container air filter 210, the
container cold heat sink 300 transporting clean cool air through
helmet inlet cooled air hose 190 to the hose supplied helmet 185.
Skirt 30 is tucked under the welder's shirt and or tie 40 is
tightened so that skirt 30 causes a majority of the air coming into
hose supplied helmet 185 to be channeled through helmet exhaust air
hose 200 back to external container 180. One construction
configuration of external container 180 has an input air section
215 and an exhaust air section 235 separated by a container baffle
260. The external container 180, is attached to the welding
operator by a suitable means, such as a belt 250 or shoulder
straps.
In operation container power wire 240 is connected to a suitable
power source such as defined in either FIG. 9, FIG. 10, FIG. 11 or
FIG. 12. Power is supplied to a thermoelectric module 330 FIG. 8
that is sandwiched between container hot heat sink 230 and helmet
cold heat sink 300. The container cold heat sink 300 and container
hot heat sink 230 are constructed of a thermally conductive
material and may contain cooling fins or pins to increase surface
area. Air is pulled through container air filter 210 by container
cooling fan 220 located in input air section 215. The air contacts
container cool heat sink 300 also located in input air section 215.
The clean cool air is transported through an opening, not shown, to
a helmet inlet cooled air hose 190 and enters through an opening,
not shown, in the top front of hose supplied helmet 185. The cool
clean air then contacts the welders head and face. The clean cooled
air then exits the hose supplied helmet 185 through an opening, not
shown, into helmet exhaust air hose 200 and enters through an
opening, not shown, in the exhaust air section 235 of external
container 180. The air then contacts container hot heat sink 230
where it assists in removing heat. The air then exits external
container 180 through exhaust air opening 280.
Referring to FIG. 5. In addition to the above operating description
also shown are container temperature control knob 270 connected to
a container control module 290. The container temperature control
knob 270 is used by the welding operator to adjust the air
temperature to the desired level. The container control module 290
uses a suitable means such as lowering voltage to adjust the amount
of cooling achieved by the thermoelectric module 330 FIG. 8 that is
sandwiched between the container hot heat sink 230 and the
container cold heat sink 300. A device could be incorporated in
container control module 290 to sense and automatically adjust
temperature to a preset level. The design of such devices is
readily achievable by one skilled in the art and is not covered in
this patent.
If the option of using container temperature control knob 270 and
container control module 290 is not employed, container cooling fan
220 could operate at one speed and a smaller capacity
thermoelectric module 330 FIG. 8 utilized such that excess cooling
cannot be achieved. It is also possible to use multiple lower power
level thermoelectric module 330 FIG. 8 and selectively tuned each
on or off with a simple switch to control temperature.
FIG. 6 shows the same elements as FIG. 5 with the elimination of
the container power wire 240 and the addition of a stored energy
device 310 that supplies the electrical energy needed to power the
container cooling fan 220 and the thermoelectric module 330 FIG. 8
that is not shown in FIG. 6 since it is sandwiched between
container hot heat sink 230 and container cold heat sink 300.
Referring to FIG. 7. The external container 180 exhaust air section
may contain an optional container hot heat sink fan 320 to increase
the total system air flow including the volume of air in contact
with container hot heat sink 230. The helmet hot heat sink fan 320
can also assist in keeping fumes and dust particles from entering
the external container exhaust air opening 280.
FIG. 13 shows an optional device to avoid possible breaking
problems if helmet power wire 130 FIG. 3 or container power wire
240 FIG. 5 were to be connected directly to power wire 390 FIG. 9.
To use this device, connector power wire 525 would be connected to
helmet power wire 130 FIG. 3 or container power wire 240 FIG. 5 and
coiled power wire 490 would be connected to power wire 390 FIG. 9.
A DC power connector 470 quickly attaches to an energy source
connector 480 using magnets 520. Electrical contacts 510 in the DC
power connector 470 protrude slightly and insert into recesses in
energy source connector 480 to the electrical connectors 510
located in energy source connector 480. The magnets 520 are offset
to assure the electrical contacts 510 meet before the magnet 520
touches the mating magnet 520. The coiled wire to power source 490
reduces the possibility of tangles. An attachment hole 500 is
affixed to the DC power connector 480 so a welder can attach it to
part of their apparel. There are a number of ways this function can
be accomplished so it is not defined by the patent claims.
FIG. 14 is another view of the DC power connector 470 showing the
electrical contacts 510 protruding and the magnet 520 recessed. The
attachment hole 500 is also shown.
FIG. 15 is a view of the welding helmet showing a possible way a
helmet segment with lens 530 can be attached with a helmet segment
lift mechanism 550. This allows the welding operator to have access
to the outside without having to remove the helmet. This can also
be utilized to allow better, wider range visibility when chipping
or grinding by having an optional clear plastic type lens 540 under
the helmet segment with lens 530. There are a number of ways this
function can be accomplished so it is not defined by the patent
claims.
CONCLUSION, RAMIFICATION, AND SCOPE
This invention describes a welding helmet that encloses a welders
head on five sides and covers a portion of their neck. This helmet
apparatus improves a welding operators working environment. It
provides clean air that reduces welding fume levels in their
breathing zone below the maximum recommended levels. It does this
while improving the working environment for one of the most
objectionable welding environmental issues, excess heat. By
providing cool air to the welders head and neck area their whole
body will feel cooler. Studies have shown cooling the head area
reduces sweating in other parts of the body.
The fact that a welders overall environment and working conditions
are improved will provide incentive for them to use the helmet. The
added advantage of having reduced burns from spatter in the head
and neck area, especially when welding overhead, is another benefit
of this fully enclosed welding helmet.
The discovery that using cooled air being exhausted from the helmet
to cool the hot side heat sink of a thermoelectric module came
about by chance when testing a device defined in patent application
Ser. No. 12/455,667 filing date May 29, 2009 entitled Clean, Cool,
Comfortable Welding Helmet.
Tests were made by delivering air into a closed container
simulating a welding helmet with a tight fitting skirt. A
commercial 45 watt thermoelectric cooling module incorporating
aluminum hot side and cold side heat sinks was employed. A 60 mm
diameter fan directed air from a duct arrangement into an opening
in the top of the simulated helmet. Air entered the duct at one end
and was channeled past the cool side heat sink. The 60 mm fan was
located at the other end of the closed duct causing the air to
enter the simulated helmet. A 55 mm hole was placed near the bottom
of the sealed simulated helmet container so the volume air flow
could be estimated by measuring flow velocity employing an impeller
driven digital anemometer. The flow rate was determined to be
approximately 200 liters/minute, more than sufficient to meet
National Institute of Occupational Safety and Health requirements.
Temperatures were measured digitally at locations before and after
the cool heat sink.
When measuring air flow rates it was observed that the cool, clean
air coming from the exit hole might be directed at the hot side
aluminum heat sink to define if an improvement in system efficiency
could be achieved. This is an unusual arrangement for a
thermoelectric module since it appears to waste cooled air. However
for this unique application the air flow must be high to meet
breathable air requirements and therefore the exhaust air could be
made available to perform a further function. A hose was attached
to the 55 mm exit exhaust hole in the simulated helmet container.
The exhaust air was directed over 8 of the 35 mm high aluminum fins
on the hot side heat sink. The voltage and amperage powering the
thermoelectric module were measured for all of the tests using a
precision shunt and digital volt meters. It was approximately the
same value for all tests ranging from 42 to 44 watts. For these
tests the airflow configuration was not optimized for the most
effective cooling of the hot heat sink. The results were very
surprising and unexpected.
The following table shows the average measurements of several tests
of each condition, with and without exhaust air cooling the heat
sink. Repeat tests showed reproducible and essentially the same
results.
TABLE-US-00001 Change in Temperature Measured Before and After Hot
Side Cooling Heat Sink Cooling of Hot After 5 Minutes After 10
Minutes After 15 Minutes Heat Sink of Operation of Operation of
Operation Convection -2.2 deg. C. -1.7 deg. C. -1.5 deg. C. Cooling
Only Enhanced with -3.9 deg. C. -3.6 deg. C. -3.6 deg. C. Cooled
Helmet Exhaust Air
As seen in the temperature results in the above table, enhancing
the cooling of the hot side heat sink increased the amount of air
cooling and reduction in air temperature by over two fold. For some
situations, this increase in efficiency of cooling provides an
ability to use a portable energy source carried on the welder's
body versus the optional external power source.
The suggested use of an external power source including that
readily available from welding power provides the energy required
for all welding situations without the need for a portable energy
source that requires recharging. This allows a fan of sufficient
capacity to draw air thorough a quality filter to capture
potentially hazardous constituents of welding fumes. This
externally supplied power allows the required cooling capacity
thermoelectric cooling module(s) to be used to significantly lower
the ambient air temperature to essentially any level desired. This
allows the welding operator to have sufficient cooling to improve
their overall work environment regardless of the ambient
conditions. The relatively small energy consumed by this helmet is
only a small fraction of the typical power used when welding and
available from a welding power supply. Typical welding power used
in arc welding ranges from 6000 to in excess of 10,000 watts
compared to the approximately 50 to perhaps 100 watts needed to
power the helmet. Therefore utilizing the welding power to supply
energy for the helmet would not affect the weld performance or
welding power supply capacity.
The above description contains many specificities to provide
illustrations of some of the embodiments. However it is understood
that other obvious items might be added such as various
construction configurations for the external canister. Functions
such as using electronic controls to set and or automatically limit
the minimum achievable temperatures were also not delineated,
although these are functionally easy to accomplish. Thus the scope
of the invention should be determined by the appended claims and
their legal equivalents, rather than the examples given.
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